US4243462A
Expired / Lapsed
US
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Heat-curable composite sheet and process for forming the same
Assignee: Nitto Denko Corp
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Filing: 1979-05-04
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Granted: 1981-01-06
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Expires: 1999-05-04
Abstract
Abstract A heat-curable multilayer composite sheet comprising a layer comprising one or more unsaturated compounds which are normally solid or liquid free radical reactive unsaturated compounds and a layer comprising a normally solid or liquid free radical initiator, the layers being bonded to each other as a laminate as separate layers at a temperature at which the free radical initiator does not lose its free radical reaction-initiating capability, and, a process for preparing a heat-curable multilayer composite sheet, which comprises coating a layer-forming material containing a normally solid or liquid free radical reactive unsaturated compound on a strippable sheet to form an unsaturated compound material layer on the strippable sheet, coating a layer-forming material containing a normally solid or liquid free radical initiator on a strippable sheet to form a free initiator layer on the strippable sheet, bringing the unsaturated compound material layer into contact with the free radical initiator layer, and bonding them to each other at a temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability.
Inventors
- 👤 Yutaka Hori
- 👤 Hidekazu Takahashi
- 👤 Makoto Sunakawa
- 👤 Ichiro Ijichi
- 👤 Kiyohiro Kamei
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 20:25
CPC Classifications
C; C09; C09J; C09J7/00; C09J7/10; B; B32; B32B; B32B27/00; B32B27/06; B32B27/065; B32B27/12; B32B27/30; B32B27/308; B32B5/00; B32B5/02; B32B5/022; B32B5/18; B32B7/00; B32B7/04; B32B7/06; B32B7/10; B32B7/12; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2451/00; C09J2301/00; C09J2301/10; C09J2301/12; C09J2301/124; C09J2301/1242; C09J2301/20; C09J2301/208; Y; Y10; Y10T; Y10T428/00; Y10T428/14; Y10T428/1452; Y10T428/24; Y10T428/24802; Y10T428/2481; Y10T428/24851; Y10T428/2486; Y10T428/24942; Y10T428/2495; Y10T428/24967; Y10T428/249921; Y10T428/249953; Y10T428/249987; Y10T428/249991; Y10T428/249992; Y10T428/26; Y10T428/266; Y10T428/28; Y10T428/2813; Y10T428/2817; Y10T428/2826; Y10T428/2839; Y10T428/2848; Y10T428/2852; Y10T428/2878; Y10T428/2887; Y10T428/2891; Y10T428/29; Y10T428/2913; Y10T428/298; Y10T428/31504; Y10T428/31511; Y10T428/31515; Y10T428/31536; Y10T428/31551; Y10T428/31645; Y10T428/31649; Y10T428/31855; Y10T428/3188; Y10T428/31895; Y10T428/31909; Y10T428/31928; Y10T442/00; Y10T442/60; Y10T442/674; Y10T442/676
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
136 words
A process for preparing a heat-curable multilayer composite sheet, which comprises coating a layer-forming material containing a normally solid or liquid free radical reactive unsaturated compound on a first strippable sheet to form an unsaturated compound material layer on the first strippable sheet, coating another layer-forming material containing a normally solid or liquid free radical initiator on a second strippable sheet to form a free radical initiator layer on the second strippable sheet, bringing the unsaturated compound material layer into contact with the free radical initiator layer, and bonding them to each other at a temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability, essentially no free radical initiator being in said layer-forming material and essentially no free radical reactive unsaturated compound being in said another layer-forming material.
Claim 2
Dependent Claim
136 words
A process for preparing a heat-curable multilayer composite sheet, which comprises coating a layer-forming material containing a normally solid or liquid free radical reactive unsaturated compound on a first strippable sheet to form an unsaturated compound material layer on the first strippable sheet, coating another layer-forming material containing a normally solid or liquid free radical initiator on a second strippable sheet to form a free radical initiator layer on the second strippable sheet, bringing the unsaturated compound material layer into contact with the free radical initiator layer, and bonding them to each other at a temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability, essentially no free radical initiator being in said layer-forming material and essentially no free radical reactive unsaturated compound being in said another layer-forming material.
Claim 3
Dependent Claim
57 words
The process of claim 1, wherein said strippable sheets are materials selected from the group consisting of glassine paper treated with silicone resin, a polyethylene film treated with silicone resin, a polyester film treated with silicone resin, a polytetrafluoroethylene film or a metal sheet having a surface treated with a silicone resin by a mold releasing method.
Claim 4
Dependent Claim
73 words
The process of claim 1, wherein said unsaturated compound is selected from the group consisting of (i) an unsaturated polymer containing at least two double bonds per molecule; (ii) a mixture of an unsaturated polymer containing at least two double bonds per molecule and an unsaturated monomer; or (iii) a mixture of an unsaturated polymer containing at least two double bonds per molecule and an unsaturated polymer containing one double bond per molecule.
Claim 5
Dependent Claim
63 words
The process of claim 3, wherein the unsaturated compound is said mixture (iii) and the amount of the double bonds in the unsaturated compound is about 10 19 to about 10 21 per gram, and the proportion of the double bonds in the polymer containing at least two double bonds per molecule is at least 0.1% based on the total double bond content.
Claim 6
Dependent Claim
34 words
The process of claim 4, wherein the proportion of double bonds in the polymer containing at least two double bonds per molecule is at least about 1.0% based on the total double bond content.
Claim 7
Dependent Claim
37 words
The process of claim 4, wherein the proportion of double bonds in the polymer containing at least two double bonds per molecule is at least 10% but less than 100% based on the total double bond content.
Claim 8
Dependent Claim
105 words
The process of claim 3, wherein said unsaturated polymer containing at least two double bonds per molecule is selected from the group consisting of (a) an acryclic unsaturated polymer of the formula ##STR2## wherein X is a hydrogen atom or a methyl group, and Y is a residue of a member selected from the group consisting of polyesters, polyurethanes, epoxy compounds and polyglycols, which has a molecular weight of not more than about 5,000; (b) an unsaturated polyester resin having a molecular weight of about 1,000 to about 50,000; or (c) an unsaturated polymer precursor having a molecular weight of about 100 to about 5,000.
Claim 9
Dependent Claim
67 words
The process of claim 7, wherein the unsaturated polymer containing at least two double bonds per molecule is an acrylic unsaturated polymer of the formula: ##STR3## wherein X is a hydrogen atom or a methyl group, and Y is a residue of a member selected from the group consisting of polyesters, polyurethanes, epoxy compounds and polyglycols, which has a molecular weight of not more than about 5,000.
Claim 10
Dependent Claim
30 words
The process of claim 8, wherein the unsaturated compound comprises the acrylic unsaturated polymer and about 0.1 to about 100% by weight, based on the polymer, of an unsaturated monomer.
Claim 11
Dependent Claim
45 words
The process of claim 1, wherein the amount of the initiator, in terms of the number of active free radicals generated from the initiator, is about 0.1 to about 1,000 per 1,000 double bonds of the unsaturated compound per unit area of the composite sheet.
Claim 12
Dependent Claim
43 words
The process of claim 1, wherein the amount of the initiator, in terms of the number of active free radicals generated from the initiator, is 1 to 100 per 1,000 double bonds of the unsaturated compound per unit area of the composite sheet.
Claim 13
Dependent Claim
43 words
The process of claim 1, wherein the amount of the initiator, in terms of the number of active free radicals generated from the initiator, is 5 to 50 per 1,000 double bonds of the unsaturated compound per unit area of the composite sheet.
Claim 14
Dependent Claim
18 words
The process of claim 1, wherein the layer on the first strippable sheet further comprises a non-reactive carrier.
Claim 15
Dependent Claim
24 words
The process of claim 13 wherein the amount of the non-reactive carrier is not more than about 500% by weight of the unsaturated compound.
Claim 16
Dependent Claim
23 words
The process of claim 13, wherein the amount of the non-reactive carrier is not more than 200% by weight of the unsaturated compound.
Claim 17
Dependent Claim
24 words
The process of claim 13, wherein the amount of the non-reactive carrier is not more than 100% by weight based on the unsaturated compound.
Claim 18
Dependent Claim
13 words
The process of claim 13, wherein the non-reactive carrier is a hot-melt adhesive.
Claim 19
Dependent Claim
18 words
The process of claim 1, wherein the layer on the second strippable sheet further comprises a non-reactive carrier.
Claim 20
Dependent Claim
24 words
The process of claim 18, wherein the amount of the non-reactive carrier is not more than about 2,000% by weight based on the initiator.
Claim 21
Dependent Claim
23 words
The process of claim 18, wherein the amount of the non-reactive carrier is not more than 1,000% by weight based on the initiator.
Claim 22
Dependent Claim
23 words
The process of claim 18, wherein the amount of the non-reactive carrier is not more than 100% by weight based on the initiator.
Claim 23
Dependent Claim
22 words
The process of claim 1, wherein the initiator is a peroxide radical initiator, an azo radical initiator or an inorganic radical initiator.
Claim 24
Dependent Claim
29 words
The process of claim 22, wherein the initiator is a peroxide radical initiator and is selected from the group consisting of a peroxide, a peracid or a peroxy ester.
Claim 25
Dependent Claim
11 words
The process of claim 1, wherein the initiator is benzoyl peroxide.
Claim 26
Dependent Claim
25 words
The process of claim 1, wherein the unsaturated compound layer and the initiator layer both have a thickness of about 0.01 to about 1.0 mm.
Claim 27
Dependent Claim
32 words
The process of claim 1, wherein said temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability is from about 40 to about 70° C.
Claim 28
Dependent Claim
29 words
The process of claim 1, wherein the layer on said first strippable sheet is heated to about 40 to about 70° C. rendering it tacky prior to said bonding.
Claim 29
Dependent Claim
31 words
The process of claim 27, wherein said bonding is accomplished by passing said two layers between two rolls having a roll pressure of about 0.5 to about 10 kg/cm 2 .
Claim 30
Dependent Claim
59 words
The process of claim 3, wherein said unsaturated monomer in mixture (ii) is selected from the group consisting of triallyl cyanurate, tolylene diallyl carbamate, diallyl isocyanurate, N-methylol acrylamide, acrylamide, methylacrylamide, N-tertiary butyl acrylamide, diacetone acrylamide, triacryl formal, ethyl acrylate, butyl acrylate, vinyl stearate, N-vinyl carbazole, divinylbenzene, divinyl ethylene glycol, maleimide, dimethyl itaconate, acenaphthylene, diallyl phthalate or trimethylol propane trimethacrylate.
Claim 31
Dependent Claim
14 words
The process of claim 7, wherein said polymer precursor is a diallyl phthalate prepolymer.
Claim 32
Dependent Claim
33 words
The process of claim 3, wherein said unsaturated compound is mixture (ii) and the amount of unsaturated monomer in the mixture is about 0.1 to about 100% by weight based on the polymer.
Claim 33
Dependent Claim
16 words
The process of claim 31, wherein said amount is about 1 to about 30% by weight.
Claim 34
Dependent Claim
82 words
The process of claim 7, wherein said unsaturated polyester resin (b) is synthesized by esterifying an acid component composed of at least one unsaturated carboxylic acid and a saturated polybasic carboxylic acid with a polyhydric alcohol and wherein said unsaturated polymer precursor (c) is synthesized by polymerizing, to an about 2 to about 50 degree or polymerization, one of more monomers having two or more double bonds per molecule in which at least one double bond per molecule remains in the precursor.
Claim 35
Dependent Claim
16 words
The process of claim 13, wherein said non-reactive carrier is a thermoplastic resin or a rubber.
Claim 36
Dependent Claim
170 words
A process for preparing a heat-curable multilayer composite sheet, which comprises coating a layer-forming material containing a normally solid or liquid free radical reactive unsaturated compound on a first strippable sheet to form an unsaturated compound material layer on the first strippable sheet, coating another layer-forming material containing a normally solid or liquid free radical initiator on a second strippable sheet to form a free radical initiator layer on the second strippable sheet, bringing the unsaturated compound material layer into contact with the free radical initiator layer, and bonding them to each other (a) without heating when one of the layers is tacky at room temperature or (b) when neither of said layers is tacky at room temperature, by heating at least one of said layers to a tackifying temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability, essentially no free radical initiator being in said layer-forming material and essentially no free radical reactive unsaturated compound being in said another layer-forming material.
Claim 37
Dependent Claim
170 words
A process for preparing a heat-curable multilayer composite sheet, which comprises coating a layer-forming material containing a normally solid or liquid free radical reactive unsaturated compound on a first strippable sheet to form an unsaturated compound material layer on the first strippable sheet, coating another layer-forming material containing a normally solid or liquid free radical initiator on a second strippable sheet to form a free radical initiator layer on the second strippable sheet, bringing the unsaturated compound material layer into contact with the free radical initiator layer, and bonding them to each other (a) without heating when one of the layers is tacky at room temperature or (b) when neither of said layers is tacky at room temperature, by heating at least one of said layers to a tackifying temperature at which the free radical initiator layer does not lose its free radical reaction initiating ability, essentially no free radical initiator being in said layer-forming material and essentially no free radical reactive unsaturated compound being in said another layer-forming material.
Claim 38
Dependent Claim
19 words
The process of claim 35 wherein bonding step (a) is used and the unsaturated compound material layer is tacky.
Claim 39
Dependent Claim
23 words
The process of claim 35 wherein bonding step (b) is used and only the unsaturated compound material layer is rendered tacky by heating.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-01-06 | 1984-07-07 | 1985-01-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-01-06 | 1988-07-07 | 1989-01-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-01-06 | 1992-07-07 | 1993-01-06 | $7700.00 | Window Closed / Lapsed |